Design of Threaded Fatigue Test Specimen for Machining

Hamza K. Akyildiz1
Department of Mechanical Engineering, Bozok University, TR-66200 Yozgat, Turkey e-mail: hkemal.akyildiz@bozok.edu.tr

Haydar Livatyali
Department of Mechanical Engineering, Istanbul Technical University, Gumussuyu, Istanbul TR-34437, Turkey e-mail: Haydar.Livatyali@mam.gov.tr

Design and machining of the fatigue test specimens have signicant effects on the duration and reliability of fatigue test. Fatigue test specimens essentially consist of three parts: the center or critical test section, which is the region where required conditions are simulated as closely as possible, and the two ends, which serve to transfer the load from the grips to the center section. When high strength materials are used for a complex geometry, such as a thread need to be tested, design and manufacturing of the specimens become more inuential on the reliability and duration of the tests. Threaded fatigue test specimens were designed, machined, and tested in a four-point rotary bending fatigue testing machine. An innovative threaded fatigue test specimen that consistently fails at the critical test section was designed, machined, and tested successfully to give the required fatigue notch factor. Because of full scale fatigue testing with threaded parts is very expensive and sometimes dangerous, evaluated threaded fatigue specimen can be used in fatigue testing and it reduces duration of the experiment more than 60% for machined threaded specimens. [DOI: 10.1115/1.4024813] Keywords: fatigue specimen design, machining, thread machining

Introduction

In general, fatigue strengths of machined threaded parts are lower than the parts that are produced by cold working processes, such as thread rolling [13]. However, the geometrical tolerances supplied by the thread rolling process are lower than machining process and the cold working processes can only be applied on materials having sufcient ductility and low hardness. As compared with cold working, machining processes are applicable to wider range of materials and have signicant superiority in geometrical precision [4]. Threads in rotary shouldered connections are produced by machining. Especially in drill pipes, there are high combined fatigue loads during the ground drilling process. The weakest part of the drill string is the threaded connection, and thus, the machining conditions of threads which are used in these connections are critical [5]. First step of the evaluating the fatigue behavior of the joint is to evaluate fatigue strengths of joint elements depending on their machining conditions. Then evaluation of the fatigue test results of the threaded connections may be well interpreted. The most suitable machining conditions and parameters must be determined for highest fatigue strength or longest life of the threaded part. To determine these conditions and parameters, it is necessary to conduct fatigue experiments with threaded parts. Fatigue experiments with actual size parts are difcult, expensive, and sometimes more dangerous or impossible and thus, down-scaled specimens are generally used in the tests [3,6]. Threaded fatigue specimen is needed to be designed for machining. Reliable threaded fatigue test specimen can be designed experimentally step by step. In this investigation, threaded fatigue test specimens were designed, machined from AISI 4340 steel which is typical drill pipe material, and fatigue experiments were conducted with them. From the initial design to the nal shape threaded specimen, all the modications on the initially designed specimen were experimentally veried. Depending on the material type and purpose of fatigue tests, different kinds of testing equipment and corresponding types of specimens are used in the fatigue tests [13,6]. A threaded fatigue test
1 Corresponding author. Contributed by the Manufacturing Engineering Division of ASME for publication in the JOURNAL OF MANUFACTURING SCIENCE AND ENGINEERING. Manuscript received July 1, 2011; nal manuscript received June 7, 2013; published online July 17, 2013. Assoc. Editor: Patrick Kwon.

specimen has a natural notch, due to thread tooth geometry. The conditions of machining of a thread are different from machining a notch with the same prole, because in thread machining, there are radial and axial feeds for every machining pass, while, in notch machining, there is only radial feed. The last passes of thread and notch machining operations are also different. In thread machining, the tool goes through thread surface with a single instant of contact in every pass, while in notch machining, the tool moves radially until it stops and begins to rub. Thus, the thread and notch surfaces are generated in different conditions. In addition, effective crosssectional areas of threaded and notched specimens are also different and eventually, fatigue strengths of the threaded and notched specimens are not equal and fatigue strengths of the threaded specimens change depending on their machining conditions [7]. Therefore, it is necessary to conduct special fatigue experiments with machined threaded specimens. When threaded specimens are used in the fatigue experiments, selecting the proper type of testing device is also critical. In cantilever-type fatigue test machine, critical test section on the fatigue specimen changes depending on bending moment along the specimen length [13,6]. Fracture occurs in the specimen according to bending moment and diameter of critical test section. When notched specimens with small diameters are tested, no problems are encountered in the cantilever-type machines. When threaded fatigue test specimens with large diameters are tested, critical test regions of the specimens cannot be restricted to a specic location as in the notched specimens, because thread is a continuous helical notch. Thus, a four-point rotary bending type fatigue test machine that can maintain constant pure bending moment over the threaded (test) zone is the most appropriate testing equipment for threaded specimens [6].

Material and Experimental Method

Material of the fatigue test specimens was AISI 4340 steel, which is one of the widely used high strength steels in the drill pipe industry especially in rotary shouldered connections in drill pipe joints. The material was hardened in oil at 800850  C and tempered at 550600  C twice, and chemical composition and the nal mechanical properties of the steel are given as averages of ten measurements in Tables 1 and 2, respectively. The thread tooth form used was the standard API V-0.040 thread form [8]. In machining threaded specimens, ISO-P type sintered carbide (78% AUGUST 2013, Vol. 135 / 041004-1

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Table 1 Element % C

Chemical composition of the AISI 4340 steel used in the experiments P Mo Si S Ni Mn Cr Al W Sb Fe

0.429 0.0161 0.047 0.232 0.0186 1.11 0.65 0.531 0.022 0.074 0.049 Remaining

Table 2 Mechanical properties of the AISI 4340 steel used in the experiments ry,0.001 (MPa) 1196 6 31 ry,0.002 (MPa) 1223 6 31 ru (MPa) 1300 6 41 Hardness (HRC) 33 6 1 %d 12 6 1 %w 48 6 2 E (MPa) 209358 6 10092

Table 3 Geometrical properties of the thread cutting tool (Kennametal LT-22ER 5API 403 KC5025) Geometric feature Thread tool prole angle Thread tool teeth height (mm) Tool prole radius (mm) Rake angle at the tooth tip (deg) Rake angle at the thread sides (deg) Clearance angle at the tool tip (deg) Clearance angle at the thread sides (deg) Tool base dimensions (mm) Inclination angle (deg) Length of the chamfer in the tool tip (mm) Value 59 deg 300 2.9 0.508 10 0 10 5 32 25 1 0.5

Fig. 1 Schematic of the Moore type four-point rotary bending fatigue testing machine: 1, specimen; 2, gripping part; 3, gripping part; 4, load arm; 5, loads; 6, xed joint; 7, bearing; 8, bearing; 9, electric motor; 10, exible coupling

Table 4

Thread machining conditions

Cutting velocity (in thread root) 88 m/min Cutting depth (in thread root) 0.1 mm Cutting conditions Coolant liquid used (10% boron oil) Specimen material AISI 4340/30HRC Tool material ISO-P type sintered coated carbide tool Thread height 1.6 mm Thread pitch 3 mm Length of the threaded section 30 mm Thread cutting method Compound straight (radial feed) Total specimen length 140190 mm Universal lathe Tos SN 50/7 kW CNC lathe Spinner Tc77-Smyc/26Kw main power Threading tool Kennametal LT-22 ER 5API 403 KC 5025

Fig. 2

Initial design of threaded fatigue test specimen

tungsten carbide (WC), 14% TiC, and 8% Co) threading tool chamfered at the tip was used (Table 3). The initial fatigue specimen design was developed according to basic mechanical knowledge, and during the preliminary tests, the design was modied to obtain more reliable results. Threaded fatigue specimens were machined under the optimum machining conditions given in the literature for the rotary shouldered connections [8]. Specimens were divided into three groups each of which was machined on a universal lathe, automat copying lathe, and computer numerical control (CNC) lathe, respectively. The machining performances of the universal and CNC lathes are given in Table 4. In the fatigue tests, a Moore type four-point rotary bending fatigue testing machine was used to provide the required pure bending moment on the testing zone of the specimens (Fig. 1). Maximum bending moment applied by the testing set-up was 240 Nm. To evaluate test results, 1216 specimens in total were used for one specimen design. All the experiments were conducted under the constant bending stress 25 MPa until the fracture happens. All cycles to fracture were between about 100,000 and 1,800,000 in all the fatigue experiments of threaded specimens The total eccentricity of the fatigue test specimens during rotation in the fatigue test machine should be less than 0.125 mm according to ASTM [6]. All the specimens were tested in the fa041004-2 / Vol. 135, AUGUST 2013

tigue test machine with the eccentricity lower than 0.125 mm. These specimens were designed based on the optimum thread machining conditions determined by Fetullayev (Fetullazade) [5] that maximize tool life and ensure precision of thread tooth geometric prole under constant machining conditions on a universal lathe. As optimum conditions, a cutting velocity of 88 m/min and a depth of cut of 0.1 mm with a cutting uid of 10% boron oil, and compound straight thread cutting method were recommended in the literature [5]. The diameter of the specimen was designed depending on the spindle speed of the universal lathe (2000 rpm) to obtain optimum cutting velocity at the universal lathe and bending moment at the fatigue testing machine. In the initial design, geometrical notch effect and machinability of threaded specimen in the universal lathe were the main considerations. Later, the same specimens were machined on a CNC lathe to check inuence of the lathe type.

Fatigue Test Specimen Design

The initial design of the threaded fatigue test specimen is given in Fig. 2. In the initial design, geometrical notch factor and machinability of the specimen in the universal lathe are mainly considered. Next, depending on the results of the fatigue tests with initial designed specimen, the initial design was modied by increasing the diameters at the grip ends to reduce the compression there (Fig. 3). In the modications of the initially designed specimen, fretting corrosion at the clamps was mainly considered. Depending on fatigue test results of the modied threaded fatigue test Transactions of the ASME

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Fig. 3

Modied threaded fatigue test specimen for machining

Fig. 4 Final design threaded fatigue test specimen for machining

specimen, last version of the threaded specimen was designed. In the last modied version of the threaded specimen, machining of the critical minor diameter of the threaded section as lowest diameter on the specimen was mainly considered. Next came up the problem of cutting such a specimen; due to conventional machining kinematics, it is not possible to reduce the diameter of the threaded section less than the side diameters on universal and CNC lathes. In the last version, screw threads were designed inward along the length of the fatigue test specimen to reduce the effective (minor) diameter of critical threaded test section. In this case, the diameters of the grip ends and transition regions would be higher than the effective diameters of the critical threaded test section and thus the highest bending stress would occur in the threaded section and the fracture will concentrate (Fig. 4). In every thread cutting condition, the minor diameter of critical threaded test section will be lower than the diameters of other sections. However, in this specimen design, machining process problems were encountered both in the universal and CNC lathes and the solution developed will be discussed in Sec. 4.
Fig. 5 Machined threaded specimens in the CNC lathe.

Machining of the Threaded Specimens

Machining of the initially designed (Fig. 2) and modied (Fig. 3) specimens was performed on both universal and CNC lathes and some machining problems were encountered during the operations. The nal design threaded specimen (Fig. 4) was machined in a copier lathe because it could not be machined in either the universal or the CNC lathe. There are two basic requirements for thread cutting. Thread cutting being a form-cutting operation, an accurately shaped and properly mounted tool is needed. The resulting thread prole is determined by the shape of the threading tool and its position relative to the workpiece. The second requirement is that the tool must move axially in a specic relationship to the rotation of the work piece [4,9]. This requirement is met through the use of the lead screw and the split nut. Proper speed ratio between the rotation of the work piece and the lead screw according to the pitch of the thread is set by means of the gear-change box in the universal lathe and by digitally controlled servo drives in the CNC lathe. During the movement in radial feed direction before every threadJournal of Manufacturing Science and Engineering

ing pass, the tool gets closer to the specimen in the radial direction and touches to the surface of the transition region of the specimen during the last pass where the nal thread height is achieved [4,9,10]. The straight threaded specimen was designed assuming the minor diameters of the threaded and the cylindrical stem zones would be equal on both sides after the last pass. However, this is not possible in practice due to radial cutting forces and exibility of the work piece (Barrel effect). The cutter dives into the cylindrical stem at the last pass (or last few passes) of threading and causes an undercut in the transition zone where the fracture during cyclic loading is initiated (Fig. 5(b)). The undercuts at the transition regions occur due to radial and tangential cutting forces and the exibility of the machining components [1114]. To ensure precision of threaded specimens, the universal lathe was stiffened (10 N/Micron) by an additional sliding bearing added as a bridge between the lead screw and the two slide ways. The nal slide rigidity was taken into consideration during machining of the specimens and radial feed was compensated to AUGUST 2013, Vol. 135 / 041004-3

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ensure the 0.1 mm depth of cut for each pass, particularly the nish pass. In addition, it also prevented harmful vibrations induced during thread machining, because one of the fundamental obstacles in improving the surface quality in machining is chatter [15]. Yet, it is very difcult to apply thread machining at the threading conditions given in both Tables 3 and 4, especially at the 88 m/min cutting velocity in the universal lathe (Thread pitch and specimen diameter). The problems during machining threaded fatigue test specimen at 88 m/min cutting velocity are the high value of cutting velocity and the shortness of the specimen. Because of the geometry of the threaded fatigue test specimen (length of the threaded and unthreaded sections) and the pitch of the thread, it is very difcult to start and stop threading with threading tool manually as the time period between starting and stopping of thread machining is very short. When machining the small sized threaded fatigue specimen at the 88 m/min and higher cutting velocities in universal lathe, this problem becomes more difcult. Initial design (Fig. 2) was machined by using extra equipment to increase the length of the specimen during machining. Minor diameter (20 mm) and length (190 mm) of the of the modied threaded fatigue specimen (Fig. 3) were mostly dened to achieve the conditions listed in Tables 3 and 4. The diameters of the specimen (Fig. 3) in the transitional regions on the left and right were obtained 20.00 mm, where the minor diameters of critical test sections were obtained about 20.1020.20 mm. Critical minor diameters of the threaded test sections of the fatigue specimen are higher than the diameter of transitional regions. The tangential and radial cutting forces were measured by means of mechanical dynamometer about 1000 N and 650 N, respectively, in the last threading pass for 1.6 mm thread height. In thread machining, radial and tangential forces are higher than cylindrical side cutting operations [16,17]. Because of higher forces, barrel effect during thread machining is more effective on the minor diameter of the threaded part. Because of the difculties during machining in the universal lathe, the same specimen was also machined between double chucks in the CNC lathe for increased rigidity and better geometrical quality. The CNC program was prepared for machining threaded specimen designed in the CNC lathe. Later, the program was tested in the simulation mode and the initial test specimen workpiece was a soft aluminum bar. Again, 88 m/min cutting velocity was taken for the 20 mm minor diameter of test section during thread machining. The dimension of specimens was measured during machining and necessary compensations values were given in the program and specimens were refashioned until the required values were obtained. In the aluminum specimen, the difference between the critical minor diameter of threaded test section and the diameter of transitional region was obtained less than about 0.01 mm. Later, using the same CNC program, threaded specimen designed (Fig. 3) was machined from 4340 steel bar with the diameter 30 mm and new compensations values for steel material were given to the CNC program. During machining, the workpiece between double chucks, synchronization problem between chucks was encountered at the starting and stopping of the two chuck spindles. The cause of the problem may be the difference of the diameters of the chucks (inertia of the chucks) and difference spindle mechanisms used in the chucks. Because of these differences, the control unit of the CNC lathe had difculty to synchronize two chucks. Synchronizing problem was noticed due to the noise during thread machining and slips marks on the grip ends of the specimens. During thread machining conditions given in Tables 3 and 4, the difference between the critical minor diameters of threaded and diameters of transitional regions is 0.050.10 mm. When compared with the soft aluminum specimen, the difference is very high. When using high strength material in thread machining, barrel effect becomes more effective on the critical minor diameter of the machined threaded specimen. The diameter difference between critical threaded test section and sides could not be 041004-4 / Vol. 135, AUGUST 2013

reduced more than 0.05 mm in the CNC lathe (Fig. 5(a)). When reducing the diameter, the threading tool was found to enter in to the specimens and machining circumferential notch in the transitional region at the beginning of the threaded critical test section (Fig. 5(b)). To eliminate this notch, the workpiece was remachined in the cutting depth higher than the depth of the notch on the transitional region of the specimen and as a result of this pass, notch disappeared. However, in this case, the difference between the critical minor diameters of threaded regions and diameter of transitional regions increased to about 0.2 mm. When considering the theoretical notch factor in the critical threaded test region is about Kt 3.5, this difference may not be important [18,19]. Threaded test specimens machined in the CNC lathe were tested in the fatigue testing machine. Results of the fatigue tests show that fractures occurred in the initial part of the critical threaded test section as they occurred in the specimens machined in the universal lathe (Figs. 6 and 7(a)). Also, fretting corrosion occurred in the grip ends of the specimens as it was seen in the previous specimens machined in universal lathe (Fig. 7). During thread machining both at the universal and CNC lathes, because of high barrel effect, it is not possible to eliminate the difference between minor diameters of critical threaded test section and the diameter of transitional regions in designed test specimen under the machining conditions dened [20]. The last modication on the threaded fatigue test specimen was also tried to machine in the CNC lathe (Fig. 4). When the user guide of the CNC lathe was investigated [21], different kinds of thread machining codes were seen. Threading codes for cylindrical surfaces and conical surfaces are included, but there is no code about machining threads on concave surfaces. Three codes were considered to machine designed threaded specimen in the CNC lathe. Three of the codes were experienced on the soft aluminum bars and none of them was capable to machine the threads in the specimen given in Fig. 4. Threads could not be machined by using these codes. The manufacturer of the CNC lathe was contacted and we are informed that a new CNC code is necessary to machine this thread tooth prole in the CNC lathe. As it is both expensive and time consuming process, it is necessary to nd a new method to machine the last modied threaded fatigue test specimen.

Fig. 6 Test results of the initial designed threaded fatigue test specimens. Specimens fractured in the outer of the critical test sections: (a) grip ends are grinded and Cu coated (b) screw threads are machined through the length of the specimen and Cu coated (c) limited threaded section and the length of grip ends are increased and ground (d) length of grip ends is shortened (e) length of the threaded section is increased and grip ends are Cu coated (f) length of the threaded section is increased and threads are machined throughout the length of the specimen (g) increased length of the threaded section and grip ends are Sn coated.

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Fig. 7 Test results of modied fatigue test specimens broken from undeveloped thread (a) and broken from fully developed thread (b)

In this case, the specimen was machined in the copier lathe. To be able to machine threaded specimen in the form given in Fig. 4, previously a template dening the thread teeth heights proles was machined in the CNC milling machine. Later, the template dening thread height was placed in the Automat copying lathe and necessary arrangements were made. After placing the template, workpiece is mounted between the chuck and the center. Threaded fatigue test specimen was machined according to the machining conditions dened before.

Results and Discussion

A comprehensive evaluation of the fatigue behavior of threaded specimens was provided by the authors previously [7], and the fractured surfaces of the threaded and notched specimens were also compared using SEM. In this study, design steps of the reliable effective threaded fatigue test specimen for machining were given. In Fig. 6, fatigue test results of the initially designed test specimens were given. Because of the simplicity of the initial design, machining of the specimen is very easy, but fatigue test results show that none of them has broken from the critical threaded test section. In this case, most of the specimens were fractured from the grip ends (Fig. 6). When machining is considered according to fatigue, machining processes cause three important effects in the surface layer of the machined part. These are residual stress, surface hardening/softening, and surface roughness. Especially during machining of thread and notch on high strength materials, residual stresses, deformation hardening, or rarely softening occurs in the surface layers among high intervals [5,2224]. These factors have different effects in wide intervals on the fatigue strengths of the threaded or notched specimens. The fatigue strength of the specimen under uctuating load heavily depends on the surface layer properties, working temperature, size and load type, etc., also specimen geometry [2,23]. Endurance limits obtained experimentally include effects of all machining and testing conditions Surface layer residual stress during machining is caused by mechanical and thermal effects. Thermal effects are claimed to cause tensile, while mechanical effects usually lead to compressive residual stresses on the part surface [2527]. A common well-known fact is that increasing surface residual tensile stress decreases the fatigue strength and increasing the compressive residual stress increases fatigue strength of the part [2,23]. Tool wear is reported to increase the thermal effects signicantly and thus it generates tensile residual stresses. When the cutting tool is sharp, plastic deformation is the main cause of the residual stresses; thermal eld plays a minor role; however, it becomes increasingly signicant with ank wear [28]. It has also been reported that tensile residual stresses are increased by increasing feed and cutting velocity [5,29,24,30]. Strain hardening of the surface layer, as well as thermal hardening or softening is also observed during machining [5,29]. Thus, because of these effects, the fatigue fracture may be apart from the critical test section of the threaded or notched fatigue specimens. Strain or phase transformation hardening, residual stresses, etc., may prevent specimen fracture from the critical test section. Journal of Manufacturing Science and Engineering

In the initially designed specimen, to prevent facture from the grip ends the length of the threaded section is increased and decreased but the fracture still remained on the grip ends. With careful inspection, signs of fretting corrosion were observed in the ground grip ends of the specimens. Different kinds of coatings and various types of lubricants were tested to eliminate the fretting corrosion on the grip ends (Fig. 6). However, none of them stopped fretting at the grip ends. Also, to reduce eccentricity, grip ends of some specimens were ground. After grinding, the total eccentricity of the specimens in the fatigue testing machine was reduced but specimens kept breaking at grip ends due to the high compression and micro friction in every cycle that led to fretting corrosion. Reducing the total eccentricity from 0.125 mm to 0.02 mm did not prevent fretting corrosion on the grip ends of the specimen. Fretting resistance of the ne turned surfaces turned out to be higher than the resistance of ground surfaces [31,32]. Then, grinding process was not used again on the grip ends of the specimens. But reducing the eccentricity was reduced amplitude of the vibration during fatigue testing. Fatigue test results of the initially designed specimen showed that this specimen cannot be used in the fatigue tests in this way and needed to be modied. Fatigue test results of the modied threaded specimen were given in Fig. 7. After the modication, the threaded specimens began to fracture from the threaded sections (Figs. 7(a) and 7(b)). However, among the specimens machined on both the universal and CNC lathes, an average 2 of 3 specimens were broken at the transition part of the critical test sections where thread teeth were not fully developed and machining conditions were also not fully obtained (Fig. 7(a)). When thread cutting simulations and cutting force calculations are considered, the fracture must have been in the critical test section at any point along the fully developed teeth (Fig. 7(b)). Consequently, this specimen design was not effective, either and thus a new design with similar effective diameter at the threaded section was needed. When modied geometry of the threaded specimen is considered according to fatigue, it can be seen that maximum theoretical stress concentration factor is ensured for the critical threaded test section of the specimen in the design. But most of the specimens have broken at entry of threaded critical test sections. Because of the barrel effect, critical minor diameter of the specimen is lower at the entry of the critical threaded test section. It is necessary to reduce critical minor test diameter of the specimens along the critical test section. For that reason, third and nal versions of the threaded specimen were designed. Fatigue test results of the nal design threaded test specimens showed that all the specimens were broken at the critical test sections which have whole developed screw threads. Fracture views of the nal design threaded fatigue test specimen were given in Fig. 8. Final design of the threaded specimen for fatigue testing has lowest crosssection at the threaded section such as to make this the critical section.

Fig. 8 Final design threaded fatigue test specimens, all of the specimens are fractured from the full developed screw threads in the critical test section, third (a), second (b), and rst whole developed thread teeth

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Conclusions

Fatigue testing is expensive and time consuming process. When used threaded specimens in the tests to get reliable and fast results are very important. In this study, most effective threaded fatigue test specimen for machining is designed. An innovative threaded four-point rotary bending fatigue test specimen representing the cutting conditions used in practice to obtain maximum thread life and geometrical tolerances dened by the API SPEC 7 standard was designed. Manufacturability of this specimen was tested on universal and CNC lathes; however, the practical and effective process could only be realized on a copier lathe. Classical thread cutting kinematics make difcult to machine threaded fatigue specimen. Because of the higher radial and tangential cutting forces in thread machining, barrel effect is heavier than cylindrical machining. The specimen may fracture out of the critical test section due to various reasons, such as barrel effect and fretting corrosion that increases fatigue notch factor at the gripping ends. To prevent this phenomenon, fretting corrosion should be considered. An innovative threaded fatigue test specimen that consistently fails at the critical test section was designed and tested in this study. Designed fatigue test specimen can be used in fatigue tests for specic purposes.

Acknowledgment
The corresponding author would like to express his ultimate gratitude and prayers of mercy and grace to Professor Eldar Fatullayev (Fetullazade) and Professor Suleyman Saritas who both supported the study and passed away in year 2008.

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